HVAC Procedure and Performance Guide

Replace oil burner (chassis and air tube)

Training for this procedure can be found in these courses:

                         131 – Oil Heat l  and  161 – Boilers l


Oil burner must be replaced according to manufacturer’s specifications. Burner must be specified type and capacity for application. Burner must be securely mounted, electrical connections must be mechanically secure and electrical continuity must be established. There must be no oil leaks and burner must ignite and operate according to manufacturer’s specifications.  Applicable safety procedures must be followed.


  1. Review job order and manufacturer’s specifications.
  2. Determine firing rate, electrical requirements, type of mounting, air-tube length and burner head.
  3. Collect tools, equipment and materials.
  4. Put on safety and protective equipment and apparel.
  5. Disconnect electrical power.
  6. Turn off fuel supply to furnace and let furnace cool.
  7. Disconnect fuel lines from burner.
  8. Drain oil into drip pan.
  9. Disconnect wiring, remove primary control unit and flame sensor, and remove burner.
  10. Verify that new burner is a suitable replacement.
  11. Check electrode gap on new burner and check nozzle size.
  12. Mount new burner:
  13. Install primary control unit and flame sensor.
  14. Connect fuel line(s).
  15. Make electrical connections.
  16. Replace oil-filter cartridge.
  17. Reconnect power, turn on fuel and bleed air from fuel line(s) (on on-line systems).
  18. Check burner oil pressure to ensure it meets specifications.
  19. Fire furnace, check ignition and adjust primary air and oil pressure.
  20. Test furnace operation; make required adjustments.
  21. If equipment does not operate to specifications, troubleshoot and make required adjustments and repairs.
  22. Leave system in required operating status.
  23. Remove safety and protective equipment and apparel.
  24. Gather tools, equipment and leftover materials, and leave work site clean.